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Mazda 1983 RX7 Service Manual

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Summary of Contents for Mazda 1983 RX7

  • Page 1 This file is available for free download at http://www.iluvmyrx7.com This file is fully text-searchable – select Edit and Find and type in what you’re looking for. This file is intended more for online viewing than printing out so some graphics may not print 100% legibly, you can zoom in on them if you need to.

  • Page 2: Cruise Control System

    CRUISE CONTROL SYSTEM Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:28PM ARTICLE BEGINNING 1983 CRUISE CONTROL SYSTEMS Mazda DESCRIPTION Main switch is used to turn system on and off. A control switch with "SET (ACCEL)"...
  • Page 3 CRUISE CONTROL SYSTEM Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:28PM Faulty actuator, control switch or unit. Actuator control cable malfunction. TESTING 1) Support vehicle with drive wheels off of ground. Turn ignition switch ON.
  • Page 4 CRUISE CONTROL SYSTEM Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:28PM ³ ³ ³ ³ Shift to D or R (1) 12 volts ÃÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³...
  • Page 5 INSTRUMENT PANEL - STANDARD Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM ARTICLE BEGINNING Switches & Instrument Panels MAZDA DESCRIPTION & OPERATION All models have a steering column mounted combination switch to control turn signals, headlights and wipers.
  • Page 6 INSTRUMENT PANEL - STANDARD Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM (1) - On Pickup, 3 ohms. (2) - On Pickup, 110 ohms. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ RESISTANCES FOR TEMPERATURE GAUGE TESTING ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 7 INSTRUMENT PANEL - STANDARD Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM To install, reverse removal procedure. COMBINATION SWITCH Removal Disconnect battery ground. Remove steering wheel. Remove column covers and snap ring at top of column (if equipped).
  • Page 8 For high speed, ground the Blue/Red terminal instead. 2) To check the park switch, apply battery voltage to the Blue wire terminal. Connect a jumper wire between Blue/White and Blue/Black. Ground the Black wire. Motor should run briefly and stop. MAZDA INTERMITTENT WIPER RELAY LOCATIONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 9 WIPER/WASHER SYSTEM Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM Model Connector Location Hatchback ....6-pin Left of instrument cluster Wagon ..... 6-pin Left of instrument cluster B2000 &...
  • Page 10 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM Installation To install, reverse removal procedure. Fig. 1: Mazda GLC Hatchback Wiring Diagram Fig. 2: Mazda GLC Wagon Wiring Diagram...
  • Page 11 WIPER/WASHER SYSTEM Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM Fig. 3: Mazda RX7 Wiring Diagram Fig. 4: Mazda B2000 and B2200 Wiring Diagram...
  • Page 12 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM Fig. 5: Mazda 626 Front Wiper Wiring Diagram (4-Door Models) Fig. 6: Mazda 626 Front Wiper Wiring Diagram (2 & 5-Door Models)
  • Page 13 WIPER/WASHER SYSTEM Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM Fig. 7: Mazda 626 Rear Wiper Wiring Diagram (4-Door Models Only) END OF ARTICLE...
  • Page 14 ELECTRICAL COMPONENT LOCATOR Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM ARTICLE BEGINNING 1983 Mazda RX7 ELECTRICAL COMPONENTS RX7 COMPONENT LOCATOR CHART ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ MISCELLANEOUS COMPONENTS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Component Component Location ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 15 ELECTRICAL COMPONENT LOCATOR Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM Cruise Control Servo On right inner fender panel. Fuse Block Below left side of dash.
  • Page 16 ELECTRICAL COMPONENT LOCATOR Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM Coolant Level Control Unit On left kick panel. Control Processing Unit On left kick panel.
  • Page 17 ELECTRICAL COMPONENT LOCATOR Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM compartment. Emission Control Unit Below left side of dash. Oscillator Control Unit At left front corner of engine...
  • Page 18 ELECTRICAL COMPONENT LOCATOR Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM Stop Light Checker On left kick panel. RELAYS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Component Component Location ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ A/C Relays (2) In left rear corner of engine compartment.
  • Page 19 ELECTRICAL COMPONENT LOCATOR Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM Choke & Check Relay In left rear corner of engine compartment. Horn Relay At left kick panel.
  • Page 20 ELECTRICAL COMPONENT LOCATOR Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM Hot Start Relay In left rear corner of engine compartment. Power Antenna Relay Under left side of dash.
  • Page 21 ELECTRICAL COMPONENT LOCATOR Article Text (p. 8) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Component Component Location ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ A/C-Heater Blower Motor Under dash in heater box. Front Washer Motor On reservoir in center right side of engine compartment.
  • Page 22 ELECTRICAL COMPONENT LOCATOR Article Text (p. 9) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:29PM Component Component Location ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Brake Fluid Level Sensor In brake master cylinder. Coolant Level Sensor On top of radiator.
  • Page 23 ELECTRICAL COMPONENT LOCATOR Article Text (p. 10) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Heat Hazard Sensor Under right side floor mat. Oil Level Sensor, (Graphic 1) In left side of oil pan.
  • Page 24 ELECTRICAL COMPONENT LOCATOR Article Text (p. 11) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Oil Level Sensor, (Graphic 2) In left side of oil pan. Oil Pressure Sending Unit On rear left side of block below oil filter.
  • Page 25 ELECTRICAL COMPONENT LOCATOR Article Text (p. 12) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Oil Thermo Sensor (Fed.), (Graphic 1) In left side of oil pan. Oil Thermo Sensor (Fed.), (Graphic 2) In left side of oil pan.
  • Page 26 ELECTRICAL COMPONENT LOCATOR Article Text (p. 13) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM SOLENOIDS/SOLENOID VALVES ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Component Component Location ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ A/C Solenoid Valve (White), (Graphic 1) In solenoid block on left side of engine.
  • Page 27 ELECTRICAL COMPONENT LOCATOR Article Text (p. 14) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Air Vent Solenoid Valve On side of carburetor. Downshift Solenoid (A/T) On left side of transmission case.
  • Page 28 ELECTRICAL COMPONENT LOCATOR Article Text (p. 15) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Leading Vacuum Control Solenoid, Valve (Brown), (Graphic 2) In solenoid block on left side of engine.
  • Page 29 ELECTRICAL COMPONENT LOCATOR Article Text (p. 16) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Relief Solenoid Valve (Blue), (Graphic 2) In solenoid block on left side of engine. Shutter Solenoid Valve (Yellow),...
  • Page 30 ELECTRICAL COMPONENT LOCATOR Article Text (p. 17) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Shutter Solenoid Valve (Yellow), (Graphic 2) In solenoid block on left side of engine. Switching Solenoid Valve (Gray),...
  • Page 31 ELECTRICAL COMPONENT LOCATOR Article Text (p. 18) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Switching Solenoid Valve (Gray), (Graphic 2) In solenoid block on left side of engine. Trailing Vacuum Control Solenoid,...
  • Page 32 ELECTRICAL COMPONENT LOCATOR Article Text (p. 19) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Trailing Vacuum Control Solenoid, (Graphic 2) In solenoid block on left side of engine. SWITCHES ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 33 ELECTRICAL COMPONENT LOCATOR Article Text (p. 20) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Brake/Stop Light Switch On top of brake pedal bracket. Clutch Switch On top of clutch pedal...
  • Page 34 ELECTRICAL COMPONENT LOCATOR Article Text (p. 21) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Coolant Temperature Switch At water pump. Inhibitor Switch (A/T) On left side of transmission case.
  • Page 35 ALTERNATOR & REGULATOR Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM ARTICLE BEGINNING 1983 Alternators & Regulators MITSUBISHI ALTERNATORS WITH INTEGRAL REGULATORS Mazda DESCRIPTION Mitsubishi alternators are conventional 3-phase, self- rectifying type units containing 6 diodes (3 positive and 3 negative) which are used to rectify current.
  • Page 36 ALTERNATOR & REGULATOR Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Fig. 1: Alternator "F" Terminal Location Terminal is located .8" (20 mm) below the hole.
  • Page 37 ALTERNATOR & REGULATOR Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM 1) After removing through bolts, insert screwdriver between front housing and stator to separate. 2) Hold the rotor in a soft jawed vice. Remove pulley nut, pulley, fan, and spacer.
  • Page 38 ALTERNATOR & REGULATOR Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Rotor Field Coil Ground Check continuity between individual slip rings and rotor core/shaft. If there is continuity, coil or slip ring is grounded, replace rotor.
  • Page 39 ALTERNATOR & REGULATOR Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Fig. 4: Exploded View of Mitsubishi Alternator END OF ARTICLE...
  • Page 40 FUSE & FLASHER LOCATIONS Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM ARTICLE BEGINNING 1983 Fuse Blocks, Flashers & Relays MAZDA Fig. 1: Fuses & Flasher Locations FUSES & FLASHER LOCATIONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 41 FUSE & FLASHER LOCATIONS Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:30PM Fuse Locations ..........Flasher Locations..........Relay Locations Check & Choke, Hot Start, A/C .......
  • Page 42 Fuse box located above driver's left knee, accessible through a removable cover, contains fuses for individual circuits. FUSE PANEL & FUSE BLOCK IDENTIFICATION (1983-85) Fig. 1: Fuse Panel Identification (1983-85) Courtesy of Mazda Motor of America Inc.
  • Page 43 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM Fig. 2: Fuse Block Identification (1983-85) Courtesy of Mazda Motor of America Inc. 1 - Empty 2 - 15 Amp Horn 3 - 15 Amp...
  • Page 44 FUSES & CIRCUIT BREAKERS Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM 21 - Empty 22 - Empty 23 - Empty 24 - Empty CAUTIONS & WARNINGS...

  • Page 45: Ignition System

    MITSUBISHI ELECTRONIC IGNITION - MAZDA ROTARY ENGINE Mazda RX7 DESCRIPTION The Mitsubishi electronic ignition system, used on the Mazda RX7 rotary engine, is unique in that it has 2 sets of spark plugs (leading and trailing). There is one set in the front rotor housing and one in the rear rotor housing.
  • Page 46 IGNITION SYSTEM Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM As each tooth passes the leading pick-up coil, the previous passing tooth approaches and becomes aligned with the trailing pick-up coil.
  • Page 47 IGNITION SYSTEM Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM Fig. 3. 2) To adjust trailing timing, loosen the screws securing the trailing vacuum unit. Move the vacuum unit outward (to advance) or inward (to retard).
  • Page 48 IGNITION SYSTEM Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM Fig. 4: Ohmmeter Hookup for Pick-Up Coil Resistance Check Replace pick-up coil and bearing plate assembly if reading is not 600-700 ohms.
  • Page 49 IGNITION SYSTEM Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM 2) Quickly operate switch "ON " and "OFF", and make sure test lamp flashes. If not, replace ignitor.
  • Page 50 STARTER - HITACHI/MITSUBISHI Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM ARTICLE BEGINNING 1983 Starters HITACHI & MITSUBISHI Mazda DESCRIPTION Starter is a conventional 12-volt, 4-pole brush-type motor, with either direct or reduction gear drive.
  • Page 51 STARTER - HITACHI/MITSUBISHI Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM B2200 Pickup ......... 3800 FWD Sedan ..........6800 RWD Wagon ..........6800 Man.
  • Page 52 STARTER - HITACHI/MITSUBISHI Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM Fig. 1: Connections for Conducting Solenoid Pull-In Test Remove solenoid-to-starter lead before testing. 2) If pinion moves outward (or plunger is pulled-in), pull-in coil is good.
  • Page 53 STARTER - HITACHI/MITSUBISHI Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM 1) Apply 12 volts between "M" (MT) terminal and the solenoid case. Pull pinion out and release it (push plunger into solenoid body by hand).
  • Page 54 STARTER - HITACHI/MITSUBISHI Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM Clean all parts. Do not use grease dissolving solvent on overrunning clutch, armature assembly, solenoid assembly or field coils due to possible damage.
  • Page 55 Adjust as necessary by changing shims between solenoid and starter yoke. 2) On Mazda B2200 models, projection distance (starter housing-to-front face of gear) should be .67" (17 mm). On Mazda RX-7 models, projection should be 1.06" (27.5 mm). Pinion Case Bearing Inspect bearing for wear and check side play.
  • Page 56 STARTER - HITACHI/MITSUBISHI Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 03:31PM Fig. 5: Disassembled View of Typical Mitsubishi Conventional Starter END OF ARTICLE...
  • Page 57 A/C SYSTEM GENERAL DIAGNOSTIC PROCEDURES Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:42PM ARTICLE BEGINNING 1983-90 AIR CONDITIONING & HEAT General Servicing Diagnostic Procedures All Import Makes & Models Diagnosis is an important first step in A/C system servicing.
  • Page 58 A/C SYSTEM GENERAL DIAGNOSTIC PROCEDURES Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:42PM 5000 ......24.92 ......+5.0 6000 ......23.92 ......+6.0 7000 ......23.02 ......
  • Page 59 A/C SYSTEM GENERAL DIAGNOSTIC PROCEDURES Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:42PM moisture or restriction. Check sensing bulb. Dry & cool to touch Frosty or warm - Check gauge readings for valve malfunction.
  • Page 60 A/C SYSTEM GENERAL DIAGNOSTIC PROCEDURES Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:42PM Fig. 2: Evaporator Temperature/Pressure A/C Chart AIR CONDITIONING DIAGNOSIS WITH GAUGES FOR SYSTEMS WITH INSUFFICIENT OR NO COOLING TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 61 A/C SYSTEM GENERAL DIAGNOSTIC PROCEDURES Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:42PM and on too rapidly. Switch NORMAL NORMAL Cycling clutch systems only - Misadjusted...
  • Page 62 A/C SYSTEM PRECAUTIONS Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:42PM ARTICLE BEGINNING AIR CONDITIONING & HEAT A/C System Precautions * PLEASE READ THIS FIRST * CAUTION: When discharging air conditioning system, use only approved refrigerant recovery/recycling equipment.
  • Page 63 A/C SYSTEM PRECAUTIONS Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:42PM Compressor oil Check article, as well as, Component Oil Replacement Quantities" chart under "A/C SYSTEM SPECS" article in this section.
  • Page 64 A/C SYSTEM PRECAUTIONS Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:42PM refrigerant into the system. On 2-piece can taps, be certain tap handle is turned fully inward to the closed position.
  • Page 65 A/C SYSTEM PRECAUTIONS Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:42PM clockwise (front seat) position. Loosen cap on high pressure manual valve connection to compressor and allow gas to escape until compressor is relieved of pressure.
  • Page 66 TRANSMISSION REMOVAL & INSTALLATION - A/T Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:50PM ARTICLE BEGINNING Automatic Transmission Removal 1983 MAZDA PICKUP REMOVAL 1) Raise vehicle and support with safety stands. Disconnect battery tube.
  • Page 67 TRANSMISSION REMOVAL & INSTALLATION - A/T Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:50PM from transmission, then disconnect both oil cooler pipes. 4) Disconnect governor tube from converter housing and transmission case (if equipped).
  • Page 68 TRANSMISSION SERVICING - A/T Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:51PM ARTICLE BEGINNING 1983 Automatic Transmission Servicing MAZDA IDENTIFICATION TRANSMISSION CODES ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Codes ............3N71B ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 69 TRANSMISSION SERVICING - A/T Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:51PM pan bolts to 36-60 INCH lbs. (4-9 N.m). Add fluid, make sure not to overfill.
  • Page 70 TRANSMISSION SERVICING - A/T Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:51PM Fig. 2: Kickdown Switch and Downshift Solenoid SHIFT LINKAGE NOTE: Before linkage is adjusted, be sure engine idle is properly set.
  • Page 71 TRANSMISSION SERVICING - A/T Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:51PM END OF ARTICLE...

  • Page 72: Brake System

    BRAKE SYSTEM Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM ARTICLE BEGINNING 1983 Brakes MAZDA GLC Wagon, Pickups, RX7 DESCRIPTION Brake system is hydraulically-operated, using a tandem master cylinder and power brake unit. Front brakes are floating caliper disc.
  • Page 73 BRAKE SYSTEM Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM wheel turns freely. Repeat procedure for opposite side. Adjust the parking brake. Install plugs in the adjusting holes.
  • Page 74 BRAKE SYSTEM Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM 2) On RX7 remove lower caliper guide pin and pivot caliper body up out of way. On GLC Wagon and Pickups remove locking clips and stopper plates.
  • Page 75 BRAKE SYSTEM Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM caliper. Slide the caliper toward the inside of the vehicle and remove the caliper. Disconnect the brake hose from the caliper.
  • Page 76 BRAKE SYSTEM Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM REAR BRAKE SHOES Removal (All Models) 1) With brake drum removed, remove brake shoe return springs, retaining springs and guide pins. Remove brake shoes.
  • Page 77 BRAKE SYSTEM Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM and dust boot. Place a piece of wood in front of piston. 2) Apply compressed air to fluid inlet and remove piston.
  • Page 78 BRAKE SYSTEM Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM Disassembly (RX7) 1) Remove dust boot retainer and boot. Turn piston counterclockwise with disc brake piston wrench (49 FA18 602), and screw out piston.
  • Page 79 BRAKE SYSTEM Article Text (p. 8) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM WHEEL CYLINDERS Disassembly Remove dust boots. Remove piston assemblies by pressing on cylinder cup to force out filling blocks and return spring.
  • Page 80 BRAKE SYSTEM Article Text (p. 9) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM Fig. 7: Exploded View of Typical Master Cylinder Some models may vary slightly. Cleaning & Inspection 1) Clean all parts in alcohol or brake fluid.
  • Page 81 BRAKE SYSTEM Article Text (p. 10) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM 3) Attach suitable tool to rear shell mounting studs. Press down on tool while rotating it clockwise to unlock rear shell.
  • Page 82 BRAKE SYSTEM Article Text (p. 11) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Ft. Lbs. (N.m) Caliper Mounting Bracket Pickups ..........40-47 (55-65) GLC Wagon ..........
  • Page 83 BRAKE SYSTEM Article Text (p. 12) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:54PM Original Thickness ........787 (20) Min. Refinish Thickness ..........Discard Thickness ........748 (19) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ DRUM SPECIFICATIONS DRUM BRAKE SPECIFICATIONS TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 84 1.1L ROTARY Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM ARTICLE BEGINNING 1983 ENGINES Mazda 1.1L Rotary ENGINE CODING ENGINE IDENTIFICATION Engine identification number is stamped on front engine housing behind the distributor.
  • Page 85 1.1L ROTARY Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Fig. 1: Exploded View of Rotors & Eccentric Shaft Assembly 3) Remove air cleaner assembly. Disconnect the following...
  • Page 86 1.1L ROTARY Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM nuts and bolts, and disconnect exhaust pipe from exhaust manifold. Support front catalytic converter. 8) Support front of transmission with jack and remove left and right engine mount nuts.
  • Page 87 1.1L ROTARY Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM washer, needle bearing, bearing housing, needle bearing, spacer and thrust plate. 6) On manual transmission models, remove clutch assembly. Use puller to remove flywheel.
  • Page 88 1.1L ROTARY Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM by sliding beyond rear rotor journal on eccentric shaft. Carefully lift out eccentric shaft to avoid damage to rotor bearing and main bearing.
  • Page 89 1.1L ROTARY Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM control valve spring free length. Free length must be 2.74" (69.6 mm). NOTE: Cap bolt and valve spring for 1983 models are painted yellow.
  • Page 90 1.1L ROTARY Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Inside Oil Seal Tracing Mark ....0004" (.01 mm) Outside Oil Seal Tracing Mark ....004" (.10 mm) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 91 1.1L ROTARY Article Text (p. 8) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Fig. 9: Stationary Gear Slot & Dowel Alignment Illustration applies to front and rear housings. Rotor Housing 1) Inspect rotor housing for signs of water or gas leakage.
  • Page 92 1.1L ROTARY Article Text (p. 9) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM NOTE: This excessive clearance would indicate a possibility of gas or water leakage. Fig. 11: Rotor Housing Thickness Check Points Check thickness at A, B, C &...
  • Page 93 1.1L ROTARY Article Text (p. 10) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Rotor Bearing Replacement 1) Place rotor bearing on support so internal gear is facing downward. Using rotor bearing replacer (49 0813 240), without adapter ring, press bearing out of rotor.
  • Page 94 1.1L ROTARY Article Text (p. 11) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Fig. 15: Apex Seal Warpage Replace if the clearance exceeds limits. 3) Using a feeler gauge, check gap between apex seal and groove in rotor.
  • Page 95 1.1L ROTARY Article Text (p. 12) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM special Bar Limit Gauge (49 0839 165) shown in Fig. 17, and is classified according to the following.
  • Page 96 1.1L ROTARY Article Text (p. 13) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM runout exceeds .0024" (.06 mm), replace shaft. 5) Oil passages in eccentric shaft are sealed by a blind plug in rear of shaft.
  • Page 97 1.1L ROTARY Article Text (p. 14) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM position by using a used inner oil seal so lip of inner oil seal sinks into position approximately .016" (.4 mm) below surface of rotor.
  • Page 98 1.1L ROTARY Article Text (p. 15) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Fig. 21: Positioning Rotor Apex for Reassembly Use care not to drop seal into port. Installing Eccentric Shaft Lubricate front rotor journal and main journal on shaft with engine lubricant.
  • Page 99 1.1L ROTARY Article Text (p. 16) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Fig. 23: Installing Protectors for Inner Sealing Rubbers Apply light coat of petroleum jelly to hold seals in place.
  • Page 100 1.1L ROTARY Article Text (p. 17) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM 4) Insert apex seal springs so that both ends of spring may support the back side of the apex seal. Install the soft seal into corner seal.
  • Page 101 1.1L ROTARY Article Text (p. 18) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Fig. 26: Tightening Sequence of Tension Bolts Replace all tension bolt sealing washers when the engine is overhauled.
  • Page 102 1.1L ROTARY Article Text (p. 19) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM chamfer downward. Slide spacer and needle bearing on eccentric shaft. Lubricate shaft and bearings, and install bearing housing.
  • Page 103 1.1L ROTARY Article Text (p. 20) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM NOTE: If end play is below specified amount, spacer thickness is too small. If end play is beyond specifications, spacer is too thick.
  • Page 104 1.1L ROTARY Article Text (p. 21) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM The crankcase capacity is 4.9 quarts (4.6L), including filter. OIL FILTER A full-flow, disposable cartridge-type filter is mounted on the rear housing.
  • Page 105 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Fig. 28: Mazda RX7 Engine Oiling System OIL PUMP NOTE: Oil pump is mounted on the front engine housing and must be overhauled with front engine cover removed.
  • Page 106 1.1L ROTARY Article Text (p. 23) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Fig. 30: Exploded View of Oil Pump Assembly 3) Insert a feeler gauge between lobes of inner and outer rotors and check clearance.
  • Page 107 1.1L ROTARY Article Text (p. 24) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM 3) To adjust oil metering pump, turn the adjusting screw clockwise to increase flow or counterclockwise to decrease flow. One completer turn will change oil discharge flow by .007-.011"...
  • Page 108 1.1L ROTARY Article Text (p. 25) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Fig. 32: Exploded View of Water Pump Reassembly 1) Install stop ring and dust seal on the shaft. Drive baffle plate onto the taper of the shaft.
  • Page 109 1.1L ROTARY Article Text (p. 26) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Cu. In..........Liters ..........Fuel System ........4 Bbl. HP @ RPM ..........Torque Ft. @ RPM ........
  • Page 110 1.1L ROTARY Article Text (p. 27) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Wear Limit .......... Seal-To-Rotor Groove Clearance ....0020-.0035 (.05-.09) Wear Limit ........0059 (.15) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ SIDE SEAL SPECIFICATIONS SIDE SEAL SPECIFICATIONS TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 111 1.1L ROTARY Article Text (p. 28) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Seal Lip Contact Width Standard In. (mm) ..Less than .02 (Less than .5) Limit In. (mm) ........
  • Page 112 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:51PM ARTICLE BEGINNING 1983-88 ENGINE PERFORMANCE Mazda VIN Code Identification MODEL IDENTIFICATION Fig. 1: VIN Code Identification VIN CODE ID EXPLANATION Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label in Fig.
  • Page 113 A - ENGINE/VIN ID Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:51PM Convertible 8 Modification Code Not Specified By Manufacturer 9 VIN Check Digit Constant For All Models...
  • Page 114 Before replacing air control valve, switching solenoid valve or relief solenoid valve, check auxiliary control unit, No. 2 water temperature switch, choke switch and choke relay as described in "Mazda RX7 Auxiliary Control Device" article in this section. Also, check throttle...
  • Page 115 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM sensor as described in "Mazda RX7 Deceleration Control System" article in this section. AIR PUMP TEST 1) With engine at normal operating temperature, inspect all hose connections for leaks.
  • Page 116 AIR INJECTION SYSTEM Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM hose. If air control valve does not respond as described, replace air control valve. Fig. 2:...
  • Page 117 AIR INJECTION SYSTEM Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM Fig. 3: Testing Relief Solenoid Valve RELIEF SOLENOID VALVE SIGNAL CHECK TEST 1) Warm engine to normal operating temperature. Connect tachometer to engine.
  • Page 118 AIR INJECTION SYSTEM Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM 7) Pull out choke knob and check that NO current flows to relief solenoid valve. Push choke knob back in. Reconnect No. 1 and No.
  • Page 119 AIR INJECTION SYSTEM Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM speed and watch voltmeter. 3) Voltmeter should read near 12V when engine speed is 1000-1200 RPM. Disconnect No. 1 water temperature switch (located behind alternator) and connect a jumper wire between both terminals in connector.
  • Page 120 AIR INJECTION SYSTEM Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:57PM 3) Place sensor and thermometer (wrapped in aluminum foil) in container filled with oil. Place a second thermometer in container of oil.
  • Page 121 Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM ARTICLE BEGINNING 1983 Exhaust Emission Systems MAZDA RX7 AUXILIARY CONTROL DEVICE DESCRIPTION In addition to the regular exhaust emission control systems previously described, RX7 models use an auxiliary control device.
  • Page 122 AUXILIARY CONTROL DEVICE Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM CHOKE RELAY 1) Disconnect coupler from relay. With engine off and no power applied, check continuity of terminals.
  • Page 123 AUXILIARY CONTROL DEVICE Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM No. 1 Switch 1) Remove switch from water pump housing. Place switch in water with a thermometer.
  • Page 124 AUXILIARY CONTROL DEVICE Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM Fig. 4: Control Unit Testing END OF ARTICLE...
  • Page 125 CARBURETOR - NIKKI 4-BBL Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:52PM ARTICLE BEGINNING 1983 Nikki Carburetors NIKKI 4-BARREL Mazda RX7 DESCRIPTION Carburetor is of 4-barrel, 2-stage design. Primary stage includes idle system, slow speed circuit, accelerator pump system and main metering system.
  • Page 126 CARBURETOR - NIKKI 4-BBL Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:52PM bend float stop to adjust. Fig. 2: Float Drop Adjustment CHOKE LINKAGE (FAST IDLE OPENING ANGLE) Close choke valve fully and measure clearance between primary throttle valve and wall of throttle bore.
  • Page 127 CARBURETOR - NIKKI 4-BBL Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:52PM Clearance should be .45-.51" (11.5-13.0 mm). Fig. 4: Choke Valve Opening Angle Adjustment NO. 2 CHOKE DIAPHRAGM 1) Disconnect vacuum sensing tube from No.
  • Page 128 CARBURETOR - NIKKI 4-BBL Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:52PM Fig. 5: Checking Automatic Choke Release CHECKING AUTOMATIC CHOKE RELEASE 1) With engine cold and ignition "OFF", pull choke knob out fully and release.
  • Page 129 CARBURETOR - NIKKI 4-BBL Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:52PM Fig. 6: Hot Start Assist Cable Adjustment THROTTLE OPENER A/C Models Only 1) Turn off all accessories. Remove fuel filler cap.
  • Page 130 CARBURETOR - NIKKI 4-BBL Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:52PM NOTE: Altitude compensator must be checked at altitudes of 1640-4920 feet. 1) Remove air cleaner and start engine. Engine should run smoothly at specified idle.
  • Page 131 CARBURETOR - NIKKI 4-BBL Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:52PM valve and choke delay valve. Remove choke heater lead, choke diaphragm No. 2 vacuum sensing tube and altitude compensator valve.
  • Page 132 CARBURETOR - NIKKI 4-BBL Article Text (p. 8) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:52PM 1) Wash all parts in clean solvent and clear all passages using compressed air. Never use wire for cleaning jets, orifices or passages.
  • Page 133 Sunday, August 26, 2001 04:58PM ARTICLE BEGINNING 1983 Exhaust Emission Systems MAZDA RX7 CHOKE RETURN & HOT START ASSIST SYSTEMS DESCRIPTION The Choke Return system prevents the choke knob from being left unreturned to prevent overheating of the exhaust system. The Hot...
  • Page 134 CHOKE - ELECTRIC ASSIST Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM Fig. 1: Choke Return and Hot Start Assist Systems TESTING CHOKE RETURN SYSTEM 1) With engine cold and ignition switch "OFF", pull choke knob out fully.
  • Page 135 HOT START ASSIST SYSTEM NOTE: Before replacing hot start motor or relay, check No. 1 water temperature switch as outlined in "Mazda RX7 Auxiliary Control Device" article in this section. 1) Inspect hot start assist cable and linkage for proper installation, no binding or sticking, and full return.
  • Page 136 CHOKE - ELECTRIC ASSIST Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM HOT START ASSIST CABLE ADJUSTMENT 1) Remove hot start assist cable lock spring from cable bracket.
  • Page 137 No. 1 anti-afterburn valve. NOTE: Before replacing No. 1 anti-afterburn valve, check auxiliary control unit as outlined in "Mazda RX7 Auxiliary Control Device" article in this section. Also check relief solenoid valve and switching solenoid valve as described in "Mazda...
  • Page 138 DECELERATION CONTROL SYSTEM Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM Fig. 1: Testing No. 1 Anti-Afterburn Valve NO. 2 ANTI-AFTERBURN VALVE 1) Warm engine to normal operating temperature. Disconnect No.
  • Page 139 DECELERATION CONTROL SYSTEM Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM Fig. 2: Testing Throttle Sensor 4) Start engine and run at 3000 RPM. Quickly decelerate engine.
  • Page 140 DECELERATION CONTROL SYSTEM Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM Fig. 3: Testing Shutter Solenoid Valve SHUTTER SOLENOID VALVE SIGNAL CHECK 1) Warm engine to normal operating temperature. Stop engine.
  • Page 141 NOTE: Before replacing shutter solenoid valve, check auxiliary control unit as outlined in "Mazda RX7 Auxiliary Control Device" article in this section. Also check relief solenoid valve and switching solenoid valve as described in "Mazda RX7 Air Injection System" article in this section.
  • Page 142 DECELERATION CONTROL SYSTEM Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM If not, loosen lock nut and turn dashpot diaphragm to adjust engine speed. END OF ARTICLE...
  • Page 143 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM ARTICLE BEGINNING 1983 ENGINE EMISSIONS Mazda Emission Control Applications 626, GLC, Pickup, RX7 EMISSION CONTROL DEVICE APPLICATIONS EMISSION CONTROL DEVICE APPLICATIONS TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ B2000 2.0L PCV, AIS, EVAP, OC, EGR, SPK, AI (1), DCS B2000 2.2L Diesel...
  • Page 144 EMISSION APPLICATION Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM ITCS ......Ignition Timing Control System ........Oxyidation Catalyst ..........Oxygen Sensor ......Positive Crankcase Ventilation .............
  • Page 145 An air vent solenoid on carburetor prevents carburetor bowl evaporated fuel from collecting in the intake manifold after hot engine shut off. With ignition off, the solenoid closes an air vent in the carbon canister, trapping the evaporated fuel. Fig. 1: Mazda RX7 Check and Cut Valve...
  • Page 146 Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM Fig. 2: Mazda RX7 Air Vent and Fuel Evaporation System CHECK & CUT VALVE This valve has 3 functions: When fuel tank pressure becomes too high, valve releases pressure to atmosphere. When vacuum becomes too high, valve allows air into tank to prevent tank from collapsing.
  • Page 147 FUEL EVAPORATION SYSTEM Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:58PM AIR VENT SOLENOID VALVE Check air vent hose for cracks or damage. Disconnect air vent hose from ventilation pipe. Slowly blow through hose. Air should pass through solenoid.
  • Page 148 FUEL PUMP - ELECTRIC Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:54PM ARTICLE BEGINNING 1983 Electric Fuel Pump MAZDA RX7, Pickup DESCRIPTION & OPERATION Electric fuel pump is mounted near fuel tank on frame member.
  • Page 149 FUEL PUMP - ELECTRIC Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:54PM RX7 ............1.5 (1400) Pickup ............8(800) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ FUEL PUMP Removal & Installation (B2000) Disconnect negative battery cable.
  • Page 150 No air should pass through compensator. Using a heat lamp, heat ø ø valve to temperature above 155 F (69 C) and try to pull air through hose. Air should pass through compensator. If not, replace compensator. Fig. 1: Mazda Hot Idle Compensator Valve END OF ARTICLE...
  • Page 151 Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:59PM ARTICLE BEGINNING 1983 Exhaust Emission Systems MAZDA RX7 IDLE COMPENSATION SYSTEM DESCRIPTION The Idle Compensation system is installed to control the air/fuel mixture under varying engine operating conditions. The system consists of idle compensator, altitude compensator and throttle opener (air conditioned models).
  • Page 152 IDLE COMPENSATION SYSTEM Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:59PM diaphragm (throttle opener) and connecting hoses and wires. The throttle opener opens the primary throttle valve when air conditioner is operated at engine speeds of 1000-1200 RPM to maintain smooth engine operation.
  • Page 153 IDLE COMPENSATION SYSTEM Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:59PM Fig. 3: Throttle Opener AIR CONDITIONER SOLENOID VALVE TEST 1) Disconnect vacuum sensing tubes from solenoid valve and vacuum port (rear of valve).
  • Page 154 NOTE: Before replacing air conditioner solenoid valve, check auxiliary control unit as outlined in "Mazda RX7 Auxiliary Control Device" article in this section. AIR CONDITIONER RELAY TEST Man. Trans. Only 1) Disconnect electrical connector from air conditioner relay.
  • Page 155 IDLE COMPENSATION SYSTEM Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:59PM continuity between No. 1 and No. 5. There should be no continuity between No. 1 and No. 3.
  • Page 156 PCV SYSTEM Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:59PM ARTICLE BEGINNING 1983 Crankcase Ventilation MAZDA B2000, B2200, GLC, 626, RX7 DESCRIPTION & OPERATION PISTON ENGINES The PCV system includes 2 hoses and a PCV valve. Air normally flows out of the valve cover hose, through the PCV valve and into combustion chambers.

  • Page 157: Pcv System

    PCV SYSTEM Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:59PM Fig. 1: B2000 Pickup Crankcase Ventilation System TESTING PISTON ENGINES All Exc. GLC FWD With engine idling at normal operating temperature, disconnect PCV valve hose at valve cover.
  • Page 158 PCV SYSTEM Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 04:59PM Fig. 2: RX7 Rotary Engine Purge Valve Air flow should be checked at port "C". Fig. 3: GLC &...
  • Page 159 3000 RPM. TESTING NOTE: For additional information and adjustments on distributor spark timing, see appropriate information in "Mazda RX7 Tune-Up Service Procedures," article in this section. VACUUM CONTROL SOLENOID VALVE 1) Disconnect vacuum sensing tubes from leading vacuum control solenoid valve (Brown dot).
  • Page 160 Before replacing vacuum control solenoid valve, check auxiliary control unit, No. 2 water temperature switch, choke switch and choke relay as described in "Mazda RX7 Auxiliary Control Device," article in this section. Also check throttle sensor as described in "Mazda RX7 Deceleration Control System,"...
  • Page 161 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:54PM ARTICLE BEGINNING 1983 Mazda Rotary Tune-Up TUNE-UP IDENTIFICATION ENGINE IDENTIFICATION Engine type code is stamped on rear rotor housing, to the rear of oil filter. Engine serial number is stamped on front rotor housing behind distributor.
  • Page 162 TUNE-UP - ROTARY Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:54PM distributor cap. Using an ohmmeter, measure resistance of wires while gently twisting wires. If resistance is not to specifications, or fluctuates from infinity to any value, replace high tension wire(s).
  • Page 163 TUNE-UP - ROTARY Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:54PM Fig. 2: Connecting Timing Light Check leading plug timing first. Fig. 3: Ignition Timing Mark Location IGNITION TIMING (DEGREES ATDC @ RPM) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 164 TUNE-UP - ROTARY Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:54PM speed to specification by turning throttle adjusting screw. NOTE: Mixture adjustment is not part of normal tune-up procedure and should not be performed unless carburetor is overhauled or vehicle fails emissions testing.
  • Page 165 TUNE-UP - ROTARY Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:54PM NOTE: Carburetor must be removed to check and/or adjust fast idle. Adjust fast idle by setting angle of primary throttle valve with choke valve fully closed.
  • Page 166 TUNE-UP - ROTARY Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:54PM All models are equipped with a Mitsubishi starter using an overrunning clutch. STARTER SPECIFICATIONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 167 TUNE-UP - ROTARY Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:54PM Oil Filter ..........15,000 Air Filter ..........30,000 Spark Plugs ..........30,000 ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ FLUID CAPACITIES ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 168 VACUUM DIAGRAMS Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:00PM ARTICLE BEGINNING 1983 EXHAUST EMISSION SYSTEMS Mazda Vacuum Diagram VACUUM DIAGRAM...
  • Page 169 VACUUM DIAGRAMS Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 05:00PM Fig. 1: Mazda RX7 Rotary Engine Vacuum Diagram END OF ARTICLE...
  • Page 170 ³ ³ 10 11 12 13 14 15 16 17 ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ 1 - Manufacturing Country Japan 2 - Make Mazda Motors Corp., Japan 3 - Type Passenger Car Passenger Car 4-5 - Model RX7 (1983-85) RX7 (1986-91) 6-7 - Body Style...

  • Page 171: Maintenance Information

    MAINTENANCE INFORMATION Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Convertible 8 - Modification Code 13BE Rotary 13BT Rotary (Turbo) 9 - VIN Check Digit Constant For All Models...
  • Page 172 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM SERVICE POINT LOCATIONS Fig. 1: Service Point Locations (Typical Non-Turbo Engine) Courtesy of Mazda Motor of America, Inc.
  • Page 173 MAINTENANCE INFORMATION Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Fig. 2: Service Point Locations (Typical Turbo Engine) Courtesy of Mazda Motor of America, Inc.
  • Page 174 MAINTENANCE INFORMATION Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Fig. 3: Service Point Locations (Non-Turbo W/Sub-Zero Start Assist) Courtesy of Mazda Motor of America, Inc.
  • Page 175 Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Fig. 4: Service Point Locations (Turbo W/Sub-Zero Start Assist) Courtesy of Mazda Motor of America, Inc. INFORMATION LABEL LOCATIONS...
  • Page 176 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Fig. 5: Information Label Locations Courtesy of Mazda Motor of America, Inc. SERVICE LABOR TIMES SERVICE LABOR TIMES TABLE (HOURS) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ 30,000 60,000...
  • Page 177 MAINTENANCE INFORMATION Article Text (p. 8) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Minimum Temperature ø ø Greater Than 0 F (-18 ....SAE 10W-30 API SG/CD Maximum Temperature ø...
  • Page 178 MAINTENANCE INFORMATION Article Text (p. 9) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM TIRE INFLATION SPECIFICATIONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application (1) Specification ý psi (kg/cm Normal Loads ........32 (2.2) Temporary Spare .........
  • Page 179 MAINTENANCE INFORMATION Article Text (p. 10) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM position from passenger's side of vehicle in case of accidental air bag inflation ANTI-LOCK BRAKE SYSTEM...
  • Page 180 MAINTENANCE INFORMATION Article Text (p. 11) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Any modification to the exhaust system on turbo models, which reduces exhaust backpressure, will lead to lean fuel mixtures and excessive spark advance.
  • Page 181 MAINTENANCE INFORMATION Article Text (p. 12) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM other objects are on or near the headlights. When working on the headlights always remove the headlight retractor fuse.
  • Page 182 MAINTENANCE INFORMATION Article Text (p. 13) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Manufacturer supplied parts and accessories are warranted against defects in material or workmanship for 12 months without regard to mileage.
  • Page 183 Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Fig. 6: Fuse Panel Identification (1983-85) Courtesy of Mazda Motor of America Inc. Fig. 7: Fuse Block Identification (1983-85) Courtesy of Mazda Motor of America Inc. 1 - Empty...
  • Page 184 Air Conditioning 20 - Empty 21 - Empty 22 - Empty 23 - Empty 24 - Empty FUSE PANEL & FUSE BLOCK IDENTIFICATION (1986-90) Fig. 8: Fuse Panel & Fuse Block Identification (1986-90) Courtesy of Mazda Motor of America, Inc.
  • Page 185 MAINTENANCE INFORMATION Article Text (p. 16) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Fuse & Circuit Breaker Identification 1 - 30 Amp Rear Defogger 2 - 15 Amp Headlights...
  • Page 186 Back-Up Battery (Air Bag) FUSE PANEL & FUSE BLOCK IDENTIFICATION (1991) Fig. 9: Fuse Panel & Fuse Block Identification (1991) Courtesy of Mazda Motor of America, Inc. Fuse & Circuit Breaker Identification 1 - 20 Amp Audio System 2 - 15 Amp...
  • Page 187 MAINTENANCE INFORMATION Article Text (p. 18) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM 7 - 30 Amp Convertible Top System 8 - 15 Amp ECAT, Fuel System, EGI & Emission Control System...
  • Page 188 MAINTENANCE INFORMATION Article Text (p. 19) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Retractor END OF ARTICLE...
  • Page 189 Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ARTICLE BEGINNING 1983-91 MAINTENANCE Mazda Maintenance & Service Intervals * PLEASE READ THIS FIRST * NOTE: All SERVICE SCHEDULES are listed for normal service vehicles. If vehicle is operated under severe service...
  • Page 190 SCHEDULED SERVICES Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM The anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment.
  • Page 191 SCHEDULED SERVICES Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM CAUTION: To avoid possible damage to vehicle use only ethylene-glycol based coolants with a mixture ratio from 44-68% anti-freeze.
  • Page 192 Failure to do so may cause turbocharger damage due to lack of oil flowing to the turbocharger bearings. SERVICE POINT LOCATIONS Fig. 1: Service Point Locations (Typical Non-Turbo Engine) Courtesy of Mazda Motor of America, Inc.
  • Page 193 SCHEDULED SERVICES Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Fig. 2: Service Point Locations (Typical Turbo Engine) Courtesy of Mazda Motor of America, Inc.
  • Page 194 SCHEDULED SERVICES Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Fig. 3: Service Point Locations (Non-Turbo W/Sub-Zero Start Assist) Courtesy of Mazda Motor of America, Inc.
  • Page 195 Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Fig. 4: Service Point Locations (Turbo W/Sub-Zero Start Assist) Courtesy of Mazda Motor of America, Inc. SEVERE & NORMAL SERVICE DEFINITIONS NOTE: Use the Severe Service schedule if the vehicle to be serviced...
  • Page 196 SCHEDULED SERVICES Article Text (p. 8) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary...
  • Page 197 SCHEDULED SERVICES Article Text (p. 9) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ³ ³ ³ ³ ³ Extended Use Of Replace Turbo: Oil & 3,000 Miles or 3 Months ³...
  • Page 198 SCHEDULED SERVICES Article Text (p. 10) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ³ ³ (since the last time), whichever comes first. ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ NORMAL MAINTENANCE SERVICE SCHEDULES CAUTION: The following service schedules refer to vehicles driven under normal operating conditions.
  • Page 199 SCHEDULED SERVICES Article Text (p. 11) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM 15,000 MILE (24,000 KM) SERVICE 15,000 MILE (24,000 KM) SERVICE ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿ ³ ³ Service Or Inspect ÃÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 200 SCHEDULED SERVICES Article Text (p. 12) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ³ ³ ³ Lubricate Chassis ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect Brake System Hoses & Lines ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 201 SCHEDULED SERVICES Article Text (p. 13) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ³ ³ ³ Check Fluid Levels and Fluid Condition ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect Coolant Level, Hoses and Clamps ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 202 SCHEDULED SERVICES Article Text (p. 14) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect/Adjust Accessory Drive Belts (Replace if Required) ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect Underhood Wiring Harnesses and Connections ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 203 SCHEDULED SERVICES Article Text (p. 15) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Suspension Bushings, Springs, Arms & Rear Jounce Bumpers ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³...
  • Page 204 SCHEDULED SERVICES Article Text (p. 16) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ Fluid Capacities ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ Application Quantity ³ ³ ³ ³ Automatic Transmission Fluid ...
  • Page 205 SCHEDULED SERVICES Article Text (p. 17) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ Application Specification ³ ³ ³ ³ Engine Oil ³ ³ Minimum Temperature ³...
  • Page 206 SCHEDULED SERVICES Article Text (p. 18) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ³ ³ ³ Check Parking Brake Operation ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Check Shift Interlock Operation ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 207 SCHEDULED SERVICES Article Text (p. 19) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ³ ³ Cooling System ³ ³ 1983-85 ......9.0-10.0 Qts. (8.5-9.5L) ³ ³ 1986-91 ³ ³...
  • Page 208 SCHEDULED SERVICES Article Text (p. 20) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM 60,000 MILE (96,000 KM) SERVICE ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿ ³ ³ Service Or Inspect ÃÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Verify Last Major Service Was Performed ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 209 SCHEDULED SERVICES Article Text (p. 21) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:13PM ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Lubricate Weatherstripping with Silicone ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Lubricate Door Hinges ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 210 SCHEDULED SERVICES Article Text (p. 22) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Manual Transmission Oil ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Rear Axle Oil ÃÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³...
  • Page 211 SCHEDULED SERVICES Article Text (p. 23) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect Exhaust System ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect C/V Joint Boots ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 212 SCHEDULED SERVICES Article Text (p. 24) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ³ ³ ³ Clean Battery and Battery Terminals ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect/Adjust Accessory Drive Belts (Replace if Required) ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 213 SCHEDULED SERVICES Article Text (p. 25) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ³ ³ ³ Oil Filter ÃÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ Lubrication Specifications ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ Application Specification ³...
  • Page 214 SCHEDULED SERVICES Article Text (p. 26) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ³ ³ Application Specification ³ ³ ³ ³ Engine Oil ³ ³ Minimum Temperature ³ ø...
  • Page 215 SCHEDULED SERVICES Article Text (p. 27) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect Fuel/Tank/Cap/Lines ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Check Operation of Horn, Wipers/Washers & All Exterior Lights ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 216 SCHEDULED SERVICES Article Text (p. 28) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Rotate Tires and Adjust Air Pressure (Including Spare) ÃÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ Replace ÃÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 217 SCHEDULED SERVICES Article Text (p. 29) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ³ ³ ³ ³ Automatic Transmission ........³ ³ Manual Transmission ........ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ 97,500 MILE (156,000 KM) SERVICE 97,500 MILE (156,000 KM) SERVICE ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿...
  • Page 218 SCHEDULED SERVICES Article Text (p. 30) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ³ ³ Service Or Inspect ÃÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Verify Last Major Service Was Performed ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 219 SCHEDULED SERVICES Article Text (p. 31) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ³ ³ ³ Inspect Front Brake Pads, Rotors and Calipers ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Lubricate Caliper Slide Rails ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 220 SCHEDULED SERVICES Article Text (p. 32) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ³ ³ ³ Inspect Exhaust System ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect C/V Joint Boots ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³...
  • Page 221 SCHEDULED SERVICES Article Text (p. 33) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect Emission Control Vacuum Hoses and Connections ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect Thermostatic Air Cleaner (If Equipped) ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 222 SCHEDULED SERVICES Article Text (p. 34) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Lubricate Front Wheel Bearings ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ Inspect Brake System Hoses & Lines ÃÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 223 SCHEDULED SERVICES Article Text (p. 35) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ Application Quantity ³ ³ ³ ³ Automatic Transmission Fluid ... 7.7-7.9 Qts. (7.3-7.5L) ³...
  • Page 224 SCHEDULED SERVICES Article Text (p. 36) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM Automatic Transmission Fluid ..7.7-7.9 Qts. (7.3-7.5L) Cooling System 1983-85 ......9.0-10.0 Qts. (8.5-9.5L) 1986-91 Turbo ........
  • Page 225 SERVICE INDICATOR & WARNING LIGHTS The warning lights will come on with the ignition. Any warning light which does not come with the ignition must be checked and repaired. Fig. 1: Dash Gauges & Warning Lights Courtesy of Mazda Motor of America Inc.
  • Page 226 SERVICE INDICATOR & WARNING LIGHTS Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:14PM BRAKE SYSTEM WARNING LIGHT Light comes on with parking brake. If light remains on, with parking brake off, fluid must be checked.
  • Page 227 TRANSMISSION REMOVAL & INSTALLATION - M/T Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:31PM ARTICLE BEGINNING Manual Transmission Removal 1983 RX7 REMOVAL & INSTALLATION Removal 1) Disconnect negative battery cable. Place gearshift lever in neutral position, and remove gearshift knob.
  • Page 228 TRANSMISSION SERVICING - M/T Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:31PM ARTICLE BEGINNING Manual Transmission Servicing 1983 B2000 & B2200 Pickups, GLC, GLC Wagon, RX7 & 626...
  • Page 229 Sunday, August 26, 2001 06:33PM ARTICLE BEGINNING 1983 Clutch Mazda - RWD GLC Wagon, RX-7, B2000 Pickup, B2200 Pickup DESCRIPTION The clutch assembly for all models is a single plate, dry disc, diaphragm spring type. The clutch release system used on the RX7 and B2000 and B2200 Pickups is hydraulic, using a firewall-mounted master cylinder and a slave cylinder attached to the clutch housing.
  • Page 230 CLUTCH Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:33PM Fig. 1: Exploded View of RWD Clutch Assembly Check clutch disc and flywheel for excessive wear, cracks or damage and release bearing for noise or roughness.
  • Page 231 CLUTCH Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:33PM in thrust direction. Replace if bearing feels rough or noisy. Inspect release fork for cracks or bends. Replace if necessary.
  • Page 232 CLUTCH Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:33PM 3) Inspect for damage to stop ring, cable ends and inner and outer cable. Check cable function. Before installing, apply molybdenum grease to bushings, pedal hook and roller.
  • Page 233 CLUTCH Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:33PM clearance exceeds .006" (.15 mm), replace defective part. Coat all components with clean brake fluid before assembly.
  • Page 234 CLUTCH Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:33PM Fig. 4: Exploded View of Clutch Slave Cylinder Inspect clutch hydraulic components for leakage and repair or replace as necessary.
  • Page 235 CLUTCH Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:33PM Fig. 5: Clutch Adjustment Locations (Except GLC Wagon) Check clutch pedal for proper height and free play.
  • Page 236 A clutch pack limited slip unit is available on RX7 models. AXLE RATIO & IDENTIFICATION All Mazda models use one basic type of rear axle assembly. Any differences in Removal & Installation or Overhaul procedures will be noted where they occur.
  • Page 237 DRIVE AXLE Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:34PM AXLE SHAFTS & BEARINGS Removal 1) Raise and support vehicle. Remove wheel. Remove brake drum and brake shoes. Disconnect and plug hydraulic line from wheel cylinder.
  • Page 238 DRIVE AXLE Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:34PM system. Fig. 3: Exploded View of Axle Shaft Assembly for Pickups If both drive axles were removed, the end play of each shaft must be measured separately.
  • Page 239 DRIVE AXLE Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:34PM friction plate, friction disc, pressure ring, side gear, pinion gear and spider. Keep parts in order for reassembly. See Fig. 1.
  • Page 240 DRIVE AXLE Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:34PM Fig. 4: Dummy Pinion Shaft and Gauge Block Never use collapsible spacer when checking pinion depth.
  • Page 241 DRIVE AXLE Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:34PM Fig. 5: Measuring Drive Pinion Installed Height The use of a dial indicator, pinion gauge set and gauge block are required for this procedure.
  • Page 242 DRIVE AXLE Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:34PM 41 ............134 (3.41) 44 ............135 (3.44) 47 ............137 (3.47) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Pinion Bearing Preload 1) Install collapsible spacer onto drive pinion assembly and install in carrier.
  • Page 243 DRIVE AXLE Article Text (p. 8) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:34PM tightening. Backlash & Side Bearing Preload 1) Place differential case assembly into carrier making sure index marks on ring and pinion gears are aligned. See Fig. 7. Install bearing adjusters and bearing caps, then tighten bearing cap nuts or bolts finger tight.
  • Page 244 DRIVE AXLE Article Text (p. 9) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 06:34PM All Others ......... 5-18 (.56-2.03) In. (mm) Ring & Pinion Backlash GLC Wagon ........0059-.0067 (.15-.17) Pickups ........

  • Page 245: Steering Column

    STEERING COLUMN Removal 1) Disconnect battery ground cable. Remove horn cap. Remove steering wheel with steering wheel puller. See Mazda in Steering Wheel & Column Switches article in this section. Remove steering column covers. Disconnect combination switch coupler and remove switch.
  • Page 246 STEERING COLUMN Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:20PM Fig. 1: GLC Wagon Steering Column RX7 steering column is similar. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...

  • Page 247: Steering Column Switches

    Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:20PM ARTICLE BEGINNING 1983 STEERING Mazda - Steering Wheel & Column Switches 626, GLC (FWD Sedan & RWD Wagon), Pickup, RX7 REMOVAL & INSTALLATION STEERING WHEEL & COMBINATION SWITCH Removal 1) Disconnect battery ground cable.
  • Page 248 STEERING COLUMN SWITCHES Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:20PM column shrouding. Remove combination switch. Disconnect electrical connector. 2) Remove screw attaching switch contact housing to steering lock body and slide out contact housing.
  • Page 249 Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:20PM ARTICLE BEGINNING 1983 STEERING Mazda - Recirculating Ball B2000 & B2200 Pickups, GLC Wagon, RX7 DESCRIPTION Steering gear is a recirculating ball type with a variable ratio, depending on turning angle of sector shaft. The worm gear and steering shaft are an integral (non-separable) unit.
  • Page 250 STEERING GEAR - MANUAL Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:20PM Fig. 1: Exploded View of Steering Gear Assembly (Pickups) Removal (GLC Wagon) 1) Disconnect negative battery cable. Remove steering wheel and switches.
  • Page 251 STEERING GEAR - MANUAL Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:20PM 1) Disconnect negative battery cable. Remove steering wheel and switches. See STEERING COLUMN SWITCHES. Remove hood, steering column covers and air duct.
  • Page 252 STEERING GEAR - MANUAL Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:20PM Fig. 3: Checking Sector Shaft Adjusting Screw End Clearance REASSEMBLY & ADJUSTMENT Steering Gear Replace oil seals if necessary.
  • Page 253 STEERING GEAR - MANUAL Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:20PM torque wrench to steering shaft upper end. If not to specifications, adjust as necessary. See Final Worm Bearing Preload table. Fill gear housing with lubricant (API GL-4 SAE 90).
  • Page 254 1983 SUSPENSION Mazda - Suspension - Front DESCRIPTION Mazda uses independent front suspension with MacPherson type struts. Strut assemblies mount between lower control arms and upper fender panels. Strut assemblies consist of inner shock absorbers and coil springs surrounding outside of strut tube housing.
  • Page 255 SUSPENSION - FRONT Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:20PM Removal 1) Raise and support vehicle. Remove wheel assembly. Remove brake caliper and hang out of the way. Remove brake caliper adapter.
  • Page 256 SUSPENSION - FRONT Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:20PM 1) Raise and support vehicle. Remove wheel assembly. Remove brake caliper and hang out of the way. Remove grease cap, cotter pin, nut lock and spindle nut.
  • Page 257 SUSPENSION - FRONT Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:20PM TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Ft. Lbs. (N.m) Backing Plate-to-Steering Knuckle ..25-33 (34-45) Ball Joint-to-Steering Knuckle .....
  • Page 258 SUSPENSION - REAR Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:21PM ARTICLE BEGINNING 1983 SUSPENSION Mazda Rear Suspension DESCRIPTION The RX7 rear suspension consists of upper and lower control links, vertically mounted shock absorbers and coil springs.
  • Page 259 SUSPENSION - REAR Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:21PM Disconnect Watt links at axle housing. Slowly lower rear axle and remove coil springs. Installation To install, reverse removal procedures.
  • Page 260 SUSPENSION - REAR Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:21PM Shock Absorber Bolt (Lower End) ...... 47-59 (64-80) Stabilizer Bar Brackets ......27-38 (37-52) Upper/Lower Link Bolts ......
  • Page 261 JACKING & HOISTING Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:21PM ARTICLE BEGINNING 1983 Jacking & Hoisting MAZDA NOTE: These illustrations are not intended to represent exact structure of each vehicle's frame, underbody or body outline.
  • Page 262 JACKING & HOISTING Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:21PM Fig. 2: B2000 & B2200 Lifting Points Fig. 3: GLC & 626 Lifting Points Fig. 4:...
  • Page 263 JACKING & HOISTING Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:21PM Fig. 5: RX7 Lifting Points END OF ARTICLE...
  • Page 264 PRE-ALIGNMENT CHECKS Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:21PM ARTICLE BEGINNING Wheel Alignment PRE-ALIGNMENT INSPECTION PROCEDURES PRE-ALIGNMENT CHECKS Before making wheel alignment adjustment, perform the following checks: 1) Tires should be equal in size and runout must not be excessive.
  • Page 265 WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:21PM ARTICLE BEGINNING 1983 Wheel Alignment MAZDA ADJUSTMENT TIRE INFLATION (COLD) Before attempting to check or adjust wheel alignment, make sure tires are properly inflated.
  • Page 266 WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:21PM Pickups Change shims between upper control arm shaft and support bracket or turn upper control arm shaft until specifications are obtained.
  • Page 267 WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:21PM 2) Turn spacer (star wheel) to make the points from rear of tire to center of crossmember equal. See Fig. 2. Turn both right and left spacers the same amount to adjust toe-in.
  • Page 268 WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Sunday, August 26, 2001 08:21PM Caster (Degrees) ......+3 2/3 +/- 1/2 (3) Camber (Degrees) ........+1 +/- 1/2 Toe-in (Inches) ........
  • Page 269 SUBJECT "ENGINE" Fuse Blows/No Start REFERENCE Mazda Motors Corp., Service Bulletin, No. 15 012/85, September, 1985 CONDITION & CAUSE Some 1979-84 RX7 vehicles may exhibit an "ENGINE" fuse that blows, preventing the engine from starting. This problem may be caused by an electrical short circuit in the wiring harness.
  • Page 270 ACCEPTABLE BATTERY DRAIN CAT. 5, NO. 017/88 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:29AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN CURRENT DRAW FROM THE BATTERY Model: All Models Bulletin No.:...
  • Page 271 ACCEPTABLE BATTERY DRAIN CAT. 5, NO. 017/88 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:29AM damaged by the excessive current. Fig. 1: Testing Currant Draw END OF ARTICLE...
  • Page 272 ALTERNATOR/REGULATOR TEST PROCESS/REPLACEMENT INFO CAT. 5, NO. 058/83 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:30AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN IC REGULATOR CHECKING PROCEDURE Models All Models Bulletin No.
  • Page 273 ALTERNATOR/REGULATOR TEST PROCESS/REPLACEMENT INFO CAT. 5, NO. 058/83 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:30AM Fig. 2: Location of "F" Terminal REPAIR PROCEDURE Please refer to the Service Information for IC regulator replacing procedure.
  • Page 274 AUDIO SYSTEM TROUBLESHOOTING PROCEDURES CAT. 15, NO. 078/89 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:30AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN AUDIO SYSTEM TROUBLESHOOTING Model All Mazda Models...
  • Page 275 AUDIO SYSTEM TROUBLESHOOTING PROCEDURES CAT. 15, NO. 078/89 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:30AM Fig. 1: Audio System Troubleshooting END OF ARTICLE...
  • Page 276 BATTERY REMOVAL/INSTALL WIRE CLIP WARNING CAT. 14, NO. 009/85 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:31AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN BATTERY CLAMP BOLT & NUT Models RX-7 Bulletin No.
  • Page 277 FUSIBLE LINK REFERENCE CHART NO. T-2-3 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:31AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN FUSIBLE LINK REFERENCE CHART Model: All Mazda Date: November 1, 1990 (Revised - April 27, 1992)
  • Page 278 FUSIBLE LINK REFERENCE CHART NO. T-2-3 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:31AM 1992 MX-3 Engine Compartment FB01-67-099 1984-86 GLC Wagon Engine Compartment 8573-66-760 ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 279 ISSUE: HIGH PITCH BUZZING NOISE AT DASH - REMOVE OSCILLATOR If you hear a high pitched buzzing noise coming from the center of the dash with the key off on a 1979-85 Mazda RX-7, the cause may be a defective oscillator. The oscillator is located under the hood, in the area near the left headlight.
  • Page 280 KEYLESS SWITCH SPEED NUT INFORMATION CAT. 15, NO. 010/85 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:32AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SPEED NUT FOR IGNITION KEY SWITCH Models GLC, 626, RX-7 &...
  • Page 281 1979-85 RX7 SUBJECT Miscellaneous Blown Fuses/Electrical Problems REFERENCE Mazda Motors Corp., Service Bulletin, No. 15 016/85, October, 1985 CONDITION & CAUSE Some 1979-85 RX7 vehicles may exhibit one or more of the following electrical problems: * RADIO, ANTENNA fuse blown...
  • Page 282 REAR WINDOW DEFROSTER GRID LINE REPAIR PROCEDURE CAT. T, NO. 015/95 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:33AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN REAR WINDOW DEFROSTER GRID LINE REPAIR...
  • Page 283 REAR WINDOW DEFROSTER GRID LINE REPAIR PROCEDURE CAT. T, NO. 015/95 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:33AM NOTE: Make sure both ends are aligned prior to attaching.
  • Page 284 REVISED WIPER LINK BUSHING CAT. 14, NO. 022/85 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:33AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WIPER LINK Models 1981-1985 RX-7 Bulletin No.
  • Page 285 TURN SIGNAL DOESN'T CANCEL - REPLACE CANCEL CAM CAT. 14, NO. 010/85 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:34AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN TURN SIGNAL SWITCH CANCEL CAM...
  • Page 286 TURN SIGNAL DOESN'T CANCEL - REPLACE CANCEL CAM CAT. 14, NO. 010/85 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:34AM Fig. 2: Turn Signal Cancel Cam 4.
  • Page 287 TURN SIGNAL DOESN'T CANCEL - REPLACE CANCEL CAM CAT. 14, NO. 010/85 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:34AM Fig. 4: Aligning Cancel Cam Tabs...
  • Page 288 1.2L ENG MODIFIED A/C COMPRESSOR BRACKET INSTRUCTION CAT. 15, NO. 124/83 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:35AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN A/C COMPRESSOR BRACKET INSTALLATION...
  • Page 289 Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:35AM PARTS INFORMATION Plain washers are not included in the 1983 RX7 kits but will be in 1984. However, these washers will be available under the following part numbers: 9995 11 022 (3.2mm, 6 pcs.) for Front Cover Stud.
  • Page 290 A/C LITE DIM/NOT ON - WIRE HARNESS CONNECTOR CAT. 16, NO. 008/85 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:35AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN AIR CONDITIONER INDICATOR LIGHT...
  • Page 291 A/C LITE DIM/NOT ON - WIRE HARNESS CONNECTOR CAT. 16, NO. 008/85 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:35AM Fig. 2: RX7 A/C Accessory Connectors...
  • Page 292 Air Conditioning system can cause higher than normal system pressures which could result in Air Conditioning System component damage. The recommended refrigerant charge for 1988 Mazda vehicles is as follows: 323, RX-7, B-Series Truck.......28 ounces 626, MX-6..........35 ounces 929.............39 ounces...
  • Page 293 DESCRIPTION This Service Bulletin contains a new Heating System Troubleshooting Manual that was developed by the Mazda Canada Quality Assurance Section. The diagnostic procedures were developed and tested in Canada during a Cold Weather Test that took place in February 1993.
  • Page 294 HEATING SYSTEM TROUBLESHOOTING CAT. U, NO. 93-04 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:36AM Fig. 1: Climate Control System USING THIS MANUAL Follow the flow charts and diagnostic procedures below to repair the complaints which were determined on the Customer Comment Sheet.
  • Page 295 HEATING SYSTEM TROUBLESHOOTING CAT. U, NO. 93-04 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:36AM 1. Collect detailed complaint information from the customer using the Customer Comment Sheet.
  • Page 296 HEATING SYSTEM TROUBLESHOOTING CAT. U, NO. 93-04 Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:36AM ³ ³ ³ humidity the windows never clear ³ ³ ³...
  • Page 297 HEATING SYSTEM TROUBLESHOOTING CAT. U, NO. 93-04 Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:36AM Fig. 2: Diagnostic Flow Chart CHECK SHEET Heater concern Item 1: Measuring Vent Outlet Air Temperature 1.
  • Page 298 HEATING SYSTEM TROUBLESHOOTING CAT. U, NO. 93-04 Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:36AM 3. Adjust the climate controls to the following settings: Function .....
  • Page 299 HEATING SYSTEM TROUBLESHOOTING CAT. U, NO. 93-04 Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:36AM NOTE: Do not perform the above checks with the engine running.
  • Page 300 HEATING SYSTEM TROUBLESHOOTING CAT. U, NO. 93-04 Article Text (p. 8) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:36AM 1. Drain the engine coolant from the radiator. 2. Remove the thermostat from the thermostat housing.
  • Page 301 HEATING SYSTEM TROUBLESHOOTING CAT. U, NO. 93-04 Article Text (p. 9) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:36AM Fig. 5: Air Intake Selector (Type A and B) Item 2 - Function Selector This selector controls the direction of the airflow from the vents.
  • Page 302 Climate Control System Shown in Fig. 8 is a typical climate control system. Detailed descriptions of each function are found under the heading "Driving Your Mazda" in the appropriate Owners Manual. Fig. 8: Climate Control System Layout END OF ARTICLE...
  • Page 303 1979-85 RX7 SUBJECT Inoperative A/C REFERENCE Mazda Motors Corp., Service Bulletin, No. 16 009/85, September, 1985 CONDITION & CAUSE Some 1979-85 RX7 vehicles may exhibit an inoperative air conditioning system. This condition may be caused by a variety of factors blowing the fusible plug on the receiver/drier.
  • Page 304 POOR A/C COOLING - ADJUST A/C THERMOSTAT CAT. 16, NO. 006/85 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:37AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN NIPPONDENSO AIR CONDITIONER Models RX-7 13B Bulletin No.
  • Page 305 POOR A/C COOLING - ADJUST A/C THERMOSTAT CAT. 16, NO. 006/85 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:37AM Fig. 2: Removing 2 Screws Securing the Thermostat ø...
  • Page 306 POOR COOLING - DIAGNOSING/REPAIR A/C LEAKS CAT. 16, NO. 033/88 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:37AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN DIAGNOSIS & REPAIR OF A/C REFRIGERANT LEAKS...
  • Page 307 POOR COOLING - DIAGNOSING/REPAIR A/C LEAKS CAT. 16, NO. 033/88 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:37AM inch a second. Whenever possible, the detector probe should be held underneath the components since the refrigerant is heaver than air.
  • Page 308 Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:25PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN RECEIVER DRIVER REPLACEMENT CRITERIA WHEN REPLACING OTHER A/C COMPONENTS Model(s): All Mazda Models with A/C (Canadian) Category: U - Heater and Air Conditioner Bulletin No.: 95-02 Date: March, 1995...
  • Page 309 RECEIVER DRIER REPLACEMENT CRITERIA (CANADIAN) CAT. U, NO. 95-02 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:25PM ³ ³ Golden Brown, Light ³ ³ Brown, Transparent, or ³...
  • Page 310 Monday, September 03, 2001 03:25PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN RECEIVER DRIVER REPLACEMENT CRITERIA WHEN REPLACING OTHER A/C COMPONENTS Model(s): All Mazda Models with A/C Category: U - Heater and Air Conditioner Systems Bulletin No.: 001/95 Date: February 15, 1995...
  • Page 311 RECEIVER DRIER REPLACEMENT CRITERIA - INFORMATION CAT. U, NO. 001/95 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:25PM ³ ³ Golden Brown, Light ³ ³ Brown, Transparent, or ³...
  • Page 312 USE OF A/C TRACER DYE SERVICE INFO CAT. U, NO. 008/97 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:26PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN USE OF A/C TRACER DYE...
  • Page 313 USE OF A/C TRACER DYE SERVICE INFO CAT. U, NO. 008/97 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:26PM b. Small amounts of the tracer dye will be found in the Recovery / Recycling tank, if recovery is necessary.
  • Page 314 USE OF A/C TRACER DYE SERVICE INFO CAT. U, NO. 008/97 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:26PM ³ ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ ³ ³...
  • Page 315 Date: October 21, 1996 DESCRIPTION Mazda Corporation does not approve of using substitute R-12 refrigerants when an A/C system requires charging. Use of these products may result in component damage and loss of warranty. If service is required on a vehicle with an R-12 system, use only new or known good recycled refrigerant.
  • Page 316 L4N71B TRANS OIL PRESSURE GAUGE ADAPTER CAT. 40, NO. 018/87 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:39AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN OIL PRESSURE GAUGE ADAPTER Model: 1983 - 1987 RX-7 A/T Bulletin No.:...
  • Page 317 PAINTING RUSTPROOF STEEL PANELS CAT. 14, NO. 070/89 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:40AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN PAINTING RUSTPROOF STEEL PANELS Model All Mazda Models...
  • Page 318 PAINTING RUSTPROOF STEEL PANELS CAT. 14, NO. 070/89 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:40AM ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÅÄÄÄÄÄÅÄÄÄÄÄÅÄÄÄÄÄÄÅÄÄÄÄÄÅÄÄÄÅÄÄÄÄÅÄÄÄÄÄ ³ ³ ³ ³ ³ ³ ³ ³ Front Door Outer Panel ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÅÄÄÄÄÄÅÄÄÄÄÄÅÄÄÄÄÄÄÅÄÄÄÄÄÅÄÄÄÅÄÄÄÄÅÄÄÄÄÄ...
  • Page 319 PAINTING RUSTPROOF STEEL PANELS CAT. 14, NO. 070/89 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:40AM Fig. 1: Location of Rustproof Steel Panels on 3 & 5-dr Hatchbacks...
  • Page 320 PAINTING RUSTPROOF STEEL PANELS CAT. 14, NO. 070/89 Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:40AM Fig. 2: Mazda 323 Wagon - Rustproof Body Panels...
  • Page 321 PAINTING RUSTPROOF STEEL PANELS CAT. 14, NO. 070/89 Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:40AM Fig. 3: Mazda 626/MX-6 - Rustproof Body Panels...
  • Page 322 PAINTING RUSTPROOF STEEL PANELS CAT. 14, NO. 070/89 Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:40AM Fig. 4: Mazda RX-7 - Rustproof Body Panels...
  • Page 323 PAINTING RUSTPROOF STEEL PANELS CAT. 14, NO. 070/89 Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:40AM Fig. 5: Mazda 929 - Rustproof Body Panels...
  • Page 324 PAINTING RUSTPROOF STEEL PANELS CAT. 14, NO. 070/89 Article Text (p. 8) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:40AM Fig. 6: Mazda MPV - Rustproof Body Panels...
  • Page 325 PAINTING RUSTPROOF STEEL PANELS CAT. 14, NO. 070/89 Article Text (p. 9) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, August 27, 2001 06:40AM Fig. 7: Mazda "B" Series - Rustproof Body Panels END OF ARTICLE...
  • Page 326 If you encounter the customer complaint on the above condition, spray anti-static agent to the surface of the seat cushion and back trim. The following anti-static agents are recommended for static electricity shock on Mazda vehicles. RECOMMENDED ANTI-STATIC PRODUCTS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ ³...
  • Page 327 SUBJECT Whistle Noise From Check & Cut Valve REFERENCE Mazda Motors Corp., Service Bulletin, No. 4 015/85, September, 1985 CONDITION & CAUSE Some 1980-85 RX7 and 1981-85 GLC vehicles may exhibit a whistle noise from the check and cut valve. The whistle noise is most noticeable at high temperature and low fuel level, and can be heard from the rear of the vehicle.
  • Page 328 Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:34PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WIND NOISE AROUND DOORS Model(s): All Mazda models except MX-5 Miata and MX-6 Category: S (09) - Body Bulletin No.: 018/98 Date:...
  • Page 329 WIND NOISE AROUND DOORS CAT. S, NO. 018/98 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:34PM NOTE: The card test can only be used to evaluate the A-pillar sealing contact.
  • Page 330 WIND NOISE AROUND DOORS CAT. S, NO. 018/98 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:34PM movement. This is done by loosening the hinge bolts and moving the door with a padded pry bar just enough to permit movement of the door.
  • Page 331 WIND NOISE AROUND DOORS CAT. S, NO. 018/98 Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:34PM Fig. 2: Grease Pattern - Measure Fig. 3: Hinge Mount - Outline...
  • Page 332 WINDSHIELD STONE CHIPPING INSPECTION CAT. S, NO. 037/96 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:33PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WINDSHIELD STONE CHIPPING INSPECTION Model(S): All Mazda Models...
  • Page 333 BRAKE CALIPER BOLT CORROSION - CLEAN & SEAL MT 0995-11 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:36PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN BRAKE CALIPER BOLTS Model(s): All Mazda Models...
  • Page 334 CORRECTION In order to effectively correct brake judder, rotor surfaces must be precisely machined. Mazda Canada Inc., has evaluated both on and off- car brake lathes and has determined that on-car lathes are more precise and greatly reduces comeback repairs.
  • Page 335 BRAKE JUDDER REPAIR (CANADIAN) CAT. P, NO. 94-06 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:36PM 1. If the vehicle is in dealer inventory and the condition is rotor rust: A.
  • Page 336 J. If the brake judder is still felt, correct the rear rotor(s) using steps "C" through "I". SERVICE TOOLS The Accu-Turn (model 8750) On-Car Brake Lathe is recommended by Mazda. The brake lathe is available through Mazda Canada's Equipment Program at 1-800-33-6687. WARRANTY INFORMATION (Applies To Vehicles Covered Under Normal Warranty.)
  • Page 337 This will cause DTV. CORRECTION In order to effectively correct brake judder, rotor surfaces must be precisely machined. Mazda has evaluated both on and off-car brake lathes and has determined that on-car lathes are more precise and greatly reduces comeback repairs.
  • Page 338 VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:36PM If the vehicle is in dealer inventory and the condition is rotor...
  • Page 339 Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:36PM SERVICE TOOLS The Accu-Tum (model 8750) On-Car Brake Lathe is recommended by Mazda. The brake lathe will be available soon from MMA's National Accounts Program at a substantial savings. When the national account is established, a Special Tools Service Bulletin will be released which will combine further details.
  • Page 340 VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95 Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:37PM Labor Operation: P0204BRX/0.6 hrs. MPV (1993 Models only) Rear Brakes/Brake Drums(s), R&R (one side) Labor Operation: P0201ARX/0.3 hrs.
  • Page 341 VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95 Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:37PM Brake Drum(s), Machine (one side) Labor Operation: P0201AMX/0.8 hrs.
  • Page 342 VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95 Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:37PM 626/MX-6 Rear Brakes/Disc Plate(s), R&R (one side) Labor Operation: P0208ARX/0.4 hrs.
  • Page 343 VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95 Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:37PM Rear Brakes/Pad(s), R&R (one sides) Labor Operation: P0209ARX/0.5 hrs.
  • Page 344 VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95 Article Text (p. 8) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:37PM Millenia Front Brakes/Disc Plate(s), R&R (one side) Labor Operation: P0102ARX/0.5 hrs.
  • Page 345 VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95 Article Text (p. 9) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:37PM Labor Operation: P0104ARX/0.4 hrs. Front Brakes/Pad(s), R&R (both sides) Labor Operation: P0104BRX/0.6 hrs.
  • Page 346 VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95 Article Text (p. 10) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:37PM Labor Operation: P0102ARX/0.4 hrs. Front Brakes/Disc Plate(s), R&R (both side) Labor Operation: P0208CRX/0.7 hrs.
  • Page 347 VIBRATION/PULSATION WHILE BRAKING - PROCEDURE CAT. P, NO. 001/95 Article Text (p. 11) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Monday, September 03, 2001 03:37PM Front Brakes/Disc Plate(s), R&R (both side) Labor Operation: P0102CRX/1.1 hrs. (2WD) Labor Operation: P0102DRX/1.6 hrs.
  • Page 348 1.2L ENG COOLING FAN DRIVE - NEW GREASE FOR COLD CAT. 3, NO. 019/83 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:17AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN 1983 RX-7 COOLING FAN DRIVE (CLUTCH)
  • Page 349 1.2L HARD CRANK/NO START - CARBON IN ROTOR/HOUSING CAT. 1, NO. 103/83 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:17AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN HARD CRANKING Models Bulletin No.
  • Page 350 1.2L HARD CRANK/NO START - CARBON IN ROTOR/HOUSING CAT. 1, NO. 103/83 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:17AM Fig. 2: Using Flywheel Turning Tool 5) Lower the vehicle.
  • Page 351 1.2L HARD CRANK/NO START - CARBON IN ROTOR/HOUSING CAT. 1, NO. 103/83 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:17AM CAUTION: Do not turn the flywheel in the direction of normal engine rotation.
  • Page 352 1.3L ENG CLUTCH VIB - REPL FLYWHEEL ALIGNMENT PINS CAT. 6, NO. 002/86 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:18AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN CLUTCH ALIGNMENT PINS...
  • Page 353 BAD SHUTTER VALVE CAUSES ROUGH IDLE/NO IDLE A bad shutter valve may cause a rough or no idle on 1982-85 Mazda RX-7 models. To test the shutter valve, remove the hose from the valve (it's located below the carburetor) and check for vacuum. If there is vacuum at idle, the shutter valve is bad and should be replaced.
  • Page 354 ENGINE STAND ADAPTOR MODIFICATIONS CAT. 40, NO. 025/88 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:18AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN ENGINE STAND ADAPTOR MODIFICATION Model: All Models Bulletin No.:...
  • Page 355 FILLING COOLING SYSTEM CAT. 3, NO. 008/87 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:18AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN ENGINE COOLANT Model: ALL MODELS Bulletin No.: 008/87...
  • Page 356 FILLING COOLING SYSTEM CAT. 3, NO. 008/87 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:18AM fully open). Check that there are no coolant leaks. Add additional coolant as needed so that the radiator is full and the coolant level is at the "FULL"...
  • Page 357 Category Date 2/10/89 DESCRIPTION When servicing Mazda vehicles, please be aware of the following installation procedure and tightening requirements of the Mazda brand oil filters. INSTALLATION PROCEDURE 1. Apply a thin film of oil to the surface of the gasket before installing the filter.
  • Page 358 INSTALLING MAZDA BRAND OIL FILTER CAT. 2, NO. 005/89 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:19AM for Oil Leakage. for Oil Leakage. TOKYO ROKI CO., LTD.
  • Page 359 OIL LEAK AT REAR STATIONARY GEAR O-RING - CAR FIX CAT. B, NO. 003/98 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:19AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN OIL LEAK AT REAR STATIONARY GEAR O-RING/ON-CAR REPLACEMENT PROCEDURE...
  • Page 360 OIL LEAK AT REAR STATIONARY GEAR O-RING - CAR FIX CAT. B, NO. 003/98 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:19AM 9. Install the (RS) gear.
  • Page 361 OIL LEAK AT REAR STATIONARY GEAR O-RING - CAR FIX CAT. B, NO. 003/98 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:19AM PARTS INFORMATION TABLE ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿...
  • Page 362 PARTIAL ENGINE (LONG BLOCK) AVAILABILITY CAT. B, NO. 004/94 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:19AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN PARTIAL ENGINE (LONG BLOCK) AVAILABILITY Model(s):...
  • Page 363 PARTIAL ENGINE (LONG BLOCK) AVAILABILITY CAT. B, NO. 004/94 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:19AM ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ ³ ³ 1990-93 B2600 (A/T)
  • Page 364 PARTIAL ENGINE (LONG BLOCK) AVAILABILITY CAT. B, NO. 004/94 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:19AM ³ ³ ³ ³ ³ Year/Model Engine P/N Gasket P/N Remarks ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´...
  • Page 365 PARTIAL ENGINE (LONG BLOCK) AVAILABILITY CAT. B, NO. 004/94 Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:19AM ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ ³ ³ 1988-89 929(3.0L SOHC)
  • Page 366 PARTIAL ENGINE (LONG BLOCK) AVAILABILITY CAT. B, NO. 004/94 Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:19AM ³ ³ ³ ³ ³ (2.5L, V-6) KL47-02-300 8AK2-02-310 ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ...
  • Page 367 Mazda does not recommend propylene glycol coolants. Available information indicates the following characteristics regarding propylene glycol coolants: * Provides less heat transfer * May not provide adequate corrosion protection (to meet Mazda specifications) * Freezing temperature is 10 - 20% higher than ethylene glycol based coolants Mazda recommends ethylene glycol and water mixture.
  • Page 368 RATTLE FROM FLOOR WHEN ACCEL - BROKEN MUFFLER HANGER CAT. 4, NO. 055/89 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:19AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN PRE-SILENCER HANGER BREAKAGE...
  • Page 369 002/96 Date: June 27, 1996 DESCRIPTION Mazda does not recommend the use of reconditioned anti-freeze. Mazda recommends ethylene glycol base coolants for all Mazda aluminum engines. Although reconditioned anti-freeze is available, this product may contain silicon particles which may be abrasive to the water pump seal.
  • Page 370 Category Date 2/14/90 DESCRIPTION Mazda Motor Corporation (MC) does not recommend the use of reconditioned anti-freeze. Please use ethylene glycol base coolant for Mazda's aluminum engines. Although it is available on the market, reconditioned anti-freeze might contain silicon particles, which could abrade the water pump seal, or it might contain other chemicals, alcohol or methanol, that may erode metal parts.
  • Page 371 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:20AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN REVISED ROTARY ENGINE PRICING Model(s): All Mazda RX-7 Models Category: Parts Flash Bulletin No.: RF 95-24 Date: October 20, 1995 DESCRIPTION The price of the Rebuilt Rotary Engines has changed.
  • Page 372 REVISED ROTORY ENGINE PRICING CAT. RF, NO. 95-24 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:20AM ³ ³ ³ ³ ³ W/ TWIN TURBO ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ END OF ARTICLE...
  • Page 373 1981-85 RX7 (High Altitude Vehicles) SUBJECT No Power, Stumble, Rough Idle, Bucking, Etc. REFERENCE Mazda Motors Corp., Service Bulletin, No. 4 014/85, August, 1985 CONDITION & CAUSE Some 1981-85 RX7 high altitude vehicles may exhibit one or more of the following driveability problems:...
  • Page 374 1.2L NEW THROTTLE SENSOR ADJUSTING PROCEDURE CAT. 1A, NO. 029/83 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:29AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN THROTTLE SENSOR CHECKING AND ADJUSTING PROCEDURES...
  • Page 375 1.3L ENG THROTLE SENSR TOOL & ADJUSTMENT INFO CAT. 40, NO. 007/85 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:30AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN THROTTLE SENSOR CHECKER...
  • Page 376 1.3L ENG THROTLE SENSR TOOL & ADJUSTMENT INFO CAT. 40, NO. 007/85 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:30AM 4. If both lamps illuminate or neither lamp illuminates, proceed as follows: * Remove the cap from the adjusting screw.
  • Page 377 1.3L ENG THROTLE SENSR TOOL & ADJUSTMENT INFO CAT. 40, NO. 007/85 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:30AM Fig. 5: Throttle Sensor Checker Attachments 4.
  • Page 378 MAZDA'S POSITION ON CaRFG * CaRFG does not affect the new vehicle or emission warranty. * Mazda recommends the use of CaRFG as a cost effective means of reducing emissions to provide cleaner air. * Vehicle and laboratory testing of CaRFG ensures that CaRFG is acceptable for customer use.
  • Page 379 CALIFORNIA REFORMULATED GASOLINE CAT. F, NO. 014/96 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:30AM operation. * Reduced benzene by approximately 50%. CaRFG AFFECT ON VEHICLE PERFORMANCE Properly blended CaRFG should have no adverse affect on vehicle performance, engine durability or fuel system components.
  • Page 380 CALIFORNIA REFORMULATED GASOLINE CAT. F, NO. 014/96 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:30AM ODOR EMITTED FROM CaRFG CaRFG is not expected to smell different from gasoline most vehicles currently use.
  • Page 381 CHOKE SYSTEM MAINTENANCE SCHEDULE/CLEANING PROCEDURE CAT. 1A, NO. 032/83 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:30AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN CHOKE SYSTEM SCHEDULED MAINTENANCE Model: 1983 RX-7, 626, GLC Bulletin No.:...
  • Page 382 * For 5-speed models: Neutral range should be selected. * For automatic transmission models: "N" or "P" range should be selected. NOTE: All Mazda vehicles meet the U.S. EPA and California emission standards when tested under the EPA certification test procedure. PREPARATION PROCEDURE...
  • Page 383 Revised: April, 24 1995 DESCRIPTION A complete line of Mazda Spark Plug Wire Sets are available from your servicing PDC. These high-quality wire sets are manufactured for Mazda by NGK. Each wire set includes the coil/wire(s) and is attractively packaged for merchandising purposes.
  • Page 384 PARTS BULLETIN - SPARK PLUG COIL/WIRE SET NO. T-1-6 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:31AM ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄ ³ ³ 1972-74 808 (1600CC) RC-ZE94A 0000-18-094A ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 385 PARTS BULLETIN - SPARK PLUG COIL/WIRE SET NO. T-1-6 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:31AM ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄ ³ ³ 1991-93 Navajo ZZLO-18-140 ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄ ³ ³...
  • Page 386 It is recommended that REGULAR UNLEADED gasoline be used in all Mazda vehicles NOT equipped with a turbocharger. All non-turbocharged Mazda vehicles are designed to perform best when REGULAR UNLEADED fuel is used. Due to the low volatility of some SUPER UNLEADED fuels, an overlean air-fuel condition may occur especially when cold.
  • Page 387 RX-7 ISSUE: OIL FILTER REPLACEMENT The oil filter is mounted face down on Mazda RX-7 engines. This makes filter replacement an unnecessarily messy job. To cut down on the spilled oil, punch two holes in the top of the filter to let the filter drain into the crankcase.
  • Page 388 SPARK PLUG CROSS-REFERENCE CHART NO. T-1-3 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:31AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SPARK PLUG CROSS-REFERENCE CHART Model: All Mazda Date: November 1, 1990 (Revised - April 27, 1992)
  • Page 389 SPARK PLUG CROSS-REFERENCE CHART NO. T-1-3 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:31AM 1979-80 GLC (Wagon) BP5ES 0660-18-110 8AG1-18-110A-BP 1980-83 GLC (Wagon) BPR5ES * 8G14-18-110...
  • Page 390 SPARK PLUG CROSS-REFERENCE CHART NO. T-1-3 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:31AM Fig. 1: Spark Plug Identification for 1986-91 RX-7 Engines END OF ARTICLE...
  • Page 391 Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:32AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN TAS (THROTTLE ADJUSTMENT SCREW) ADJUSTMENT Model(s): All Mazda Models with Fuel Injection Category: F (01) - Fuel & Emission Control Bulletin No.: 014/98 Date:...
  • Page 392 TAS (THROTTLE ADJUSTMENT SCREW) LOCATION/ADJUSTMENT CAT. F, NO. 014/98 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:32AM Fig. 1: Throttle Adjustment Screw Locations END OF ARTICLE...
  • Page 393 SUBJECT Whistle Noise From Check & Cut Valve REFERENCE Mazda Motors Corp., Service Bulletin, No. 4 015/85, September, 1985 CONDITION & CAUSE Some 1980-85 RX7 and 1981-85 GLC vehicles may exhibit a whistle noise from the check and cut valve. The whistle noise is most noticeable at high temperature and low fuel level, and can be heard from the rear of the vehicle.
  • Page 394 APPLICATION 1983-86 RX7 SUBJECT Clutch Chatter/Judder REFERENCE Mazda Motors Corp., Service Bulletin, No. 6 003/86, April, 1986 CONDITION & CAUSE Some 1983-86 RX7 vehicles may exhibit clutch chatter/judder. This condition may be caused by the clutch disc. REPAIR To repair the above mentioned complaint, install a new service clutch disc.
  • Page 395 1.3L ENG CLUTCH VIB - REPL FLYWHEEL ALIGNMENT PINS CAT. 6, NO. 002/86 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:43AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN CLUTCH ALIGNMENT PINS...
  • Page 396 Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:43AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN HARD SHIFT TO 2ND GEAR AFTER COLD START Model(s): 1980-91 Mazda RX-7 (non-turbo) 1990-91 Mazda Miata Category: Bulletin No.: 004/92 Date: 7/7/92...
  • Page 397 HARD SHIFT TO 2ND GEAR AFTER COLD START - NEW PARTS CAT. J, NO. 004/92 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:43AM MX-5 Miata JM1NA351*M*232720...
  • Page 398 IMPROVED SPEEDO GEAR SLEEVE TO ELIMINATE LEAKS CAT. 7, NO. 027/87 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:43AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SPEEDOMETER DRIVEN GEAR SLEEVE...
  • Page 399 IMPROVED SPEEDO GEAR SLEEVE TO ELIMINATE LEAKS CAT. 7, NO. 027/87 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:43AM Long Bed JM2UF211 H0603331 Cab Plus JM211311 ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ...
  • Page 400 M & R TYPE TRANS HARD SHIFT COLD - NEW GEAR OIL CAT. 7, NO. 062/89 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:43AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN...
  • Page 401 MANUAL TRANS NEW BEARING COVER BOLTS/TORQUE CAT. 7, NO. 002/84 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:43AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN MODIFICATION OF BEARING COVER BOLTS Model: B2000, B2200, &...
  • Page 402 MANUAL TRANS NEW BEARING COVER BOLTS/TORQUE CAT. 7, NO. 002/84 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:43AM RX-7 12A: JM1FB331 E0819695 February, 1984 13B: JM1FB332 E0819695...
  • Page 403 Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:44AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN MANUAL TRANSMISSION SHIM ADJUSTMENTS Model: Mazda 1981-90 RX-7 & B-Series, 1988-90 929, 1999-90 MPV, 1990 MX-5 Miata Date: March 2, 1990 001/90 Group:...
  • Page 404 MANUAL TRANSMISSION SHIM ADJUSTMENTS CAT. J, NO. 001/90 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:44AM Fig. 1: Manual Transmission Application Chart 1. Install the synchronizer ring and 5th gear.
  • Page 405 MANUAL TRANSMISSION SHIM ADJUSTMENTS CAT. J, NO. 001/90 Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:44AM Fig. 2: Retaining Ring Installation (M-Type) Note: If the "C" washers are not pushed fully forward in the mainshaft groove the measurement will be incorrect.
  • Page 406 MANUAL TRANSMISSION SHIM ADJUSTMENTS CAT. J, NO. 001/90 Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:44AM Fig. 4: Installing Rear Bearing (M-Types) NOTE: If the "C" washers will not fit into the rear mainshaft groove, select the proper thickness "C"...
  • Page 407 MANUAL TRANSMISSION SHIM ADJUSTMENTS CAT. J, NO. 001/90 Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:44AM Fig. 6: Retaining Ring Installation (R-Type) Note: If the "C" washers are not pushed fully forward in the mainshaft groove the measurement will be incorrect.
  • Page 408 MANUAL TRANSMISSION SHIM ADJUSTMENTS CAT. J, NO. 001/90 Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:44AM Fig. 8: Rear Bearing Installation (R-Type) Note: If the "C" washers will not fit into the rear mainshaft groove, select the proper thickness "C"...
  • Page 409 May 1995 DESCRIPTION Remanufactured Transmissions and Transaxles which are supplied by Mazda Canada Inc., are rebuilt by M.A.N.A. (Mazda North America Inc.). This division of Mazda supplies remanufactured units for both Canada and United States. In their continued efforts to upgrade the quality of these remanufactured units they are looking for more information on what initially failed and why.
  • Page 410 REMANUFACTURED TRANS (CANADIAN) - DIAGNOSIS SHEET CAT. J, NO. 95-02 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:44AM Fig. 1: Example of Warranty Tag 3. The defective unit must be shipped to the Quality Assurance Centre...
  • Page 411 Two copies of this Service Bulletin are being supplied to each dealer. Please give the second copy to the Mazda Parts Manager. NOTE: Five copies of the Automatic Transmission Diagnosis Information Sheet are being supplied with this bulletin.
  • Page 412 REMANUFACTURED TRANS (CANADIAN) - DIAGNOSIS SHEET CAT. J, NO. 95-02 Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:44AM Fluid Condition: ____ Burnt ____ Normal Fluid Level:...
  • Page 413 REAR WHEEL DRIVE PINION HEIGHT ADJUSTMENT INFO CAT. 9, NO. 014/83 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:49AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN PINION HEIGHT ADJUSTMENT Models All Rear Drive Models Bulletin No.
  • Page 414 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:50AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN ALIGNMENT SPECIFICATIONS Models: 1993-95 Mazda Models (Except 1994-95 B-Series) (Canada) Category: N - Steering Bulletin No.: 95-02 Date: January, 1995 APPLICABLE MODELS All models except 1994-95 B-Series.
  • Page 415 ALIGNMENT SPECIFICATIONS (CANADIAN) CAT. N, NO. 95-02 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:50AM ³ ³ ³ ³ ³ indicated is not mentioned. ³ ³...
  • Page 416 ALIGNMENT SPECIFICATIONS AND TOLERANCES -INFORMATION CAT. N, NO. 001/95 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:50AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN ALIGNMENT SPECIFICATIONS Model(s): All Mazda Models (except Navajo &...
  • Page 417 ALIGNMENT SPECIFICATIONS AND TOLERANCES -INFORMATION CAT. N, NO. 001/95 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:50AM ³ ³ ³ ñ ñ ³ ³ Rear Camber (Difference 1.5) degrees...
  • Page 418 ALUMINUM WHEEL TIRE CHANGE - CENTER HUB DAMAGE INFO CAT. 12, NO. 002/85 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:51AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN TIRE CHANGERS FOR ALUMINUM WHEEL Models RX-7, 626 &...
  • Page 419 Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:51AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN CHECKING PROCEDURE FOR POWER STEERING BOOT LEAKAGE Model(s): All Mazda Models with Rack/Pinion Category: N - Steering System Bulletin No.: 004/97 Date:...
  • Page 420 CHECKING PROCEDURE FOR POWER STEERING BOOT LEAKAGE CAT. N, NO. 004/97 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:51AM gear. CAUTION: DO NOT keep the steering wheel fully turned to the locked position for more than five seconds.
  • Page 421 HIGH STEERING WHEEL EFFORT - VERIFY CONDITION MT 0995-05 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:51AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN STEERING WHEEL EFFORT Model(s): All Mazda...
  • Page 422 INSTALLATION OF TIRE CHAINS CAT. Q, NO. 005/93 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:51AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN INSTALLATION OF TIRE CHAINS Model(s): All Mazda Models Category: "Q"...
  • Page 423 REVISED IDLER ARM/DUST SEAL CAT. 10, NO. 023/83 Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:51AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN IDLER ARM MODIFICATION Models 1983 GLC (WAGON), RX-7 Bulletin No.
  • Page 424 Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:51AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN STEERING WHEEL SLIGHTLY OFF CENTER Models: All Mazda Models Through 1995 Except B-Series & Navajo Category: Bulletin No.: 005/95 Date: 3/15/95 DESCRIPTION The steering wheel on some models may be slightly off center.
  • Page 425 STEERING WHEEL SLIGHTLY OFF CENTER - PROCEDURE CAT. N, NO. 005/95 Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:51AM ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ´ ³ ³ ³ ³ 4 cyl.
  • Page 426 1. Manufacturer: Mazda Motor Corporation 2. Description of the Defect: Recall Surveillance tests performed by EPA found some MY-1982 and 1983 Mazda RX-7's to be in non- compliance of Federal exhaust emission standards for HC and CO. Mazda's investigation determined the non-compliance to be due to excessively-rich air fuel mixture and premature deterioration of the vehicle's catalyst.
  • Page 427 25,500 0.60 4.28 0.45 ÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄ 7. Anticipated Follow-Up Action: Mazda will conduct a voluntary emission recall campaign to repair all subject vehicles. The voluntary emission recall report is shown below. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ VOLUNTARY EMISSION RECALL REPORT 1. Description of Each Class of Subject Vehicles AFFECTED VEHICLES ÄÄÄÄÄÄÂÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄ...
  • Page 428 Saturday, September 08, 2001 09:58AM 5. Procedure to Obtain Correction The repair will be done by authorized Mazda dealers only. The repair will be available on and after February 27, 1987. The time required for the repair will be about 1.2 hours.
  • Page 429 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:58AM B. Notification The owners of subject vehicles will be notified on and after February 27, 1987 by first class mail.
  • Page 430 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:58AM the monolith converters (N201 40 4000 for 1982 model and N231 40 4000 for 1983 model) to be commonly used for both year models.
  • Page 431 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 6) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:58AM * Replacement of catalyst pellets in the Catalytic Converter. NOTE: The catalyst pellets replacement should be performed under the exchange operation.
  • Page 432 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 7) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:58AM Fig. 2: Disconnecting Hose From Air Pump 2. Insert the secondary air orifice (included in the kit) about 1 inch into the air pump side of the hose.
  • Page 433 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 8) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM moving. 4. Measure the clearance between the lock nut and the bracket (clearance "A"...
  • Page 434 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 9) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM 1. Remove the hot air duct. See Fig. 6. Fig. 6: Hot Air Duct Location 2.
  • Page 435 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 10) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM Fig. 8: Sliding Clamp on Air Hose (Air Control Valve Side) 4.
  • Page 436 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 11) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM Fig. 10: Removing Cap and Switching Valve 7. Enlarge the hole as shown in Fig. 11 with the 4.2 mm drill bit provided.
  • Page 437 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 12) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM Fig. 12: Blowing Chips off with Air Gun 9. Re-install the cap and switching valve removed in Step 6.
  • Page 438 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 13) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM Fig. 13: Check Valve Position and Orientation 11. Re-install the air control valve.
  • Page 439 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 14) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM Fig. 14: Location of Drain Plugs No. 1 and 2 ø...
  • Page 440 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 15) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM Fig. 16: Converter in Level Position 7. Tap the converter repeatedly at points "A" and "B" until all pellets are in.
  • Page 441 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 16) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM Fig. 18: Location of Drain Hole No. 2 11. Pour all the pellets from the plastic bag containing a smaller amount of pellets (0.6 L) into the drain hole No.
  • Page 442 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 17) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM CAUTION: * Allow the exhaust system to cool to avoid injury.
  • Page 443 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 18) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM by using pliers in order to get the space for loosening the catalytic converter nuts.
  • Page 444 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 19) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM Fig. 23: Removing Catalytic Converter 8. Hold the removed converter level and securely in a vise as shown in Fig.
  • Page 445 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 20) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM Fig. 24: Installing New Lock Washer on Converter 12. Install the exchange converter on the customer's vehicle using new gaskets, new spring washers and new nuts.
  • Page 446 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 21) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM 18. Fill out the recall label with your dealer code and the repair date, then affix this label on the passenger side's door.
  • Page 447 Recall Campaign Recall No. 23702 Dear Customer, According to our records, you own a 1982 or 1983 model Mazda RX-7. Tests performed by the Environmental Protection Agency (U.S. EPA) suggest that Federally-certified 1982 and 1983 Mazda RX-7s may not conform with Federal emission standards for exhaust emissions. To...
  • Page 448 CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS Article Text (p. 23) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:59AM Mazda ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ END OF ARTICLE...
  • Page 449 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 09:57AM ARTICLE BEGINNING NHTSA RECALL BULLETIN Model(s): 1983 Mazda GLC (FWD Sedan) 1983 Mazda RX7 Campaign No: 85V108000 Number of Affected Vehicles: 136526 Beginning Date of Manufacture:...
  • Page 450 WIRING DIAGRAM SYMBOLS Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 10:05AM ARTICLE BEGINNING WIRING DIAGRAMS How To Use The Wiring Diagrams WIRING DIAGRAMS INTRODUCTION The wiring diagrams and technical service bulletins, containing wiring diagram changes, are obtained from the domestic and import manufacturers.
  • Page 451 WIRING DIAGRAM SYMBOLS Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 10:05AM product, there is a Legend for the wiring diagrams that has been created to make locating components easier. For these articles, there will be a COMPONENT LOCATION MENU title in the article main menu.
  • Page 452 WIRING DIAGRAM SYMBOLS Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 10:05AM Blue ........Brown ........Clear ........Dark Blue .... DK BLU ....
  • Page 453 WIRING DIAGRAM SYMBOLS Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 10:05AM Fig. 9: Defogger Grid Fig. 10: Fuse Fig. 11: Fusible Link Fig. 12: Ground Fig. 13: Glow Plug Resistor (In-Line) or Mirror Heater Fig.
  • Page 454 WIRING DIAGRAM SYMBOLS Article Text (p. 5) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 10:05AM Fig. 24: Two Pin Switch Fig. 25: Variable Resistor or Potentiometer END OF ARTICLE...
  • Page 455 WIRING DIAGRAMS Article Text 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 10:05AM ARTICLE BEGINNING 1983 Wiring Diagrams Mazda IDENTIFICATION Fig. 1: Engine Compartment...
  • Page 456 WIRING DIAGRAMS Article Text (p. 2) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 10:05AM Fig. 2: Fuse Block & Underdash...
  • Page 457 WIRING DIAGRAMS Article Text (p. 3) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 10:05AM Fig. 3: Underdash (Cont.) & Instrument Panel...
  • Page 458 WIRING DIAGRAMS Article Text (p. 4) 1983 Mazda RX7 For www.iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, September 08, 2001 10:05AM Fig. 4: Rear Compartment & Accessories END OF ARTICLE...

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